1. Optimization of Micro-
machining Processes
DR ANAND J KULKARNI
SYMBIOSIS CENTER FOR RESEARCH AND INNOVATION, SYMBIOSIS INTERNATIONAL
(DEEMED UNIVERSITY), PUNE, INDIA
EMAIL: ANAND.KULKARNI@SITPUNE.EDU.IN; KULK0003@NTU.EDU.SG
APOORVA SHASTRI, ANIKET NARGUNDKAR
SYMBIOSIS INSTITUTE OF TECHNOLOGY, SYMBIOSIS INTERNATIONAL (DEEMED
UNIVERSITY), PUNE, INDIA
2. Outline
ο΅ Non Traditional Machining Processes (NTM)
ο΅ Need of Optimization and Techniques
ο΅ Electric Discharge Machining (EDM)
ο΅ Abrasive Water Jet Machining (AWJM)
ο΅ Micro-Milling
ο΅ Micro-Drilling with CFRP Application
ο΅ Micro-Turning
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3. Manufacturing Processes
ο΅ Definition: the application of mechanical, physical, and chemical
processes to convert the geometry, properties, and/or shape of raw
material into finished parts or products.
ο΅ Primary Processes
ο΅ Machining Processes
ο΅ Metal Forming Processes
ο΅ Joining Processes
ο΅ Surface Finishing Processes
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4. 20th & 21st Century Applications &
Materials
ο΅ Aerospace
ο΅ Military
ο΅ Automobile
ο΅ Electronic Gadgets
ο΅ Complex Designs, many more, β¦
ο΅ Materials and alloys necessitate
ο΅ high strength-to-weight ratio
ο΅ high stiffness and toughness
ο΅ high heat capacity
ο΅ thermal conductivity, etc.
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5. 20th & 21st Century Applications &
Traditional Machining Processes
ο΅ Traditional Machining Processes, Chip Removal Processes
ο΅ Generation of High Temperatures and Stresses
ο΅ Challenges:
ο΅ Rapid Deterioration of the Cutting Tools
ο΅ Inferior Quality of Machined Parts
ο΅ Innovative and Complex Designs
ο΅ Demanding Tolerance Requirements
ο΅ Cost Reduction
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6. Non Traditional Machining (NTM)
Processes
NTM
Processes
Mechanical
Processes
AWJM USM
Electro
Chemical
Processes
ECM
Electro
Thermal
Processes
EDM
Tool based
Micro
Machining
Micro
Turning
Micro
Milling
Micro
Drilling
Sustainable
Machining
(MQL,
Cryogenic)
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7. Need for Optimization
ο΅ Dynamic and Market competition driven manufacturing
ο΅ Reduced time-to-market: shorter manufacturing time
ο΅ Minimal manufacturing costs: efficient use of all the resources
ο΅ High and Expected quality of highly customized products
ο΅ Growing needs for safety
ο΅ Determine optimal process parameter settings
ο΅ Productivity
ο΅ Quality
ο΅ Cost of Production
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13. Electric Discharge Machining
(EDM)
ο΅ Controlled Spark-Erosion
ο΅ high strength temperature resistant materials and alloys (hardened
steel, carbide, etc.) with intricate geometries
G
Tool (-ve)
Work Piece (+ve)
Dielectric
Medium
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14. EDM: Process Parameters/Variables
& Objectives
ο΅ The Process Parameters/Variables
ο΅ Discharge Current (π1)
ο΅ Gap Voltage (π2)
ο΅ Pulse on-time (π3)
ο΅ Pulse off-time (π4)
ο΅ Gap between the work piece and the tool
ο΅ Dielectric medium.
ο΅ Objectives
ο΅ Minimize Surface Roughness (π π)
ο΅ Minimize Relative Electrode Wear Rate (π πΈππ )
ο΅ Maximizing Material Removal Rate (ππ π )
G
Tool (-ve)
Work Piece (+ve)
Dielectric
Medium
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Muthuramalingam and Mohan (2015)
Gopalakannan and Senthilvelan (2014)
20. Abrasive Water Jet Machining
(AWJM)
ο΅ Very high velocity fine abrasive particles impinge on the work piece
ο΅ Effective for hard, brittle material, tough, hard to machine materials (titanium,
stainless steel, high-strength temperature-resistant alloys, ceramics, refractories, fiber-reinforced
composites, super alloys, etc.)
Gupta et al 2017
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25. Tool Based Micro-machining
Processes
ο΅ Todayβs manufacturing field involve
ο΅ increased number of functions
ο΅ Miniaturization of parts/dimensions
ο΅ Advantages of tool based micromachining
ο΅ Productivity
ο΅ Efficiency
ο΅ Flexibility
ο΅ Cost effectiveness
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26. Tool Based Micro-machining
Processes Methods of Micro
Fabrication
Material
Deposition
(Additive)
Physical Vapour
Deposition
Chemical Vapour
Deposition
Lithography
Material
Removal/Mecha
nical Processes
(Subtractive)
Conventional
Tool Based
Processes such
as Micro Turning,
Micro Drilling
and Micro Milling
Advanced
Processes such as
Micro-EDM,
Micro- ECM
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39. Micro-Drilling of CFRP
Composites for Aerospace App
ο΅ Minimization of Cutting Forces in x, y and z directions induced in
micro drilling of Carbon Fiber Reinforced Plastic (CFPR) composite
materials for aerospace applications.
ο΅ CFRP Properties
ο΅ High Stiffness
ο΅ High Strength to Weight Ratio
ο΅ Good Damping Capacity
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44. Optimization of Micro-turning
Process
Process
Cutter
Dim
Objective
Function
Algorithms Applied
GA SA PSO
Variations of CI
Multi-CIroulette
wheel
fbest fbetter
alienatio
n
Micro
Turning
0.2 mm
Nose
radius
π π
Mean 0.45 0.45 0.46 0.46 0.45 0.45 0.46 0.46
S.D. 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Best 0.45 0.45 0.45 0.45 0.45 0.45 0.45 0.45
Run Time 1.64 2.80 1.21 0.04 0.03 0.04 0.10 0.39
ππ
Mean 0.63 0.64 0.63 0.63 0.63 0.63 0.63 0.63
S.D. 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Best 0.63 0.64 0.63 0.63 0.63 0.63 0.63 0.63
Run Time 1.42 2.78 0.89 0.06 0.04 0.04 0.10 0.38
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45. For all the MATLAB Codes 45
www.sites.google.com/site/oatresearch/
or
Google: OAT Research Lab
46. Thank you
Anand J Kulkarni PhD, MASc, BEng, DME
Associate Professor
Symbiosis Center for Research and Innovation
Symbiosis International (Deemed University)
Pune 412 115, MH, India
Email: anand.kulkarni@sitpune.edu.in
kulk0003@ntu.edu.sg; anandmasc@gmail.com
URL: sites.google.com/site/oatresearch/anand-jayant-kulkarni
Ph: 91 20 6193 6790
ResearcherID: www.researcherid.com/rid/O-3585-2016
ORCID ID: orcid.org/0000-0001-6242-9492
Google Scholar: scholar.google.ca/citations?user=IAvtDokAAAAJ&hl=en
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